Oral care implement and method of manufacturing an oral care implement

ABSTRACT

A method of manufacturing an oral care implement, comprises: (a) providing a head and a first part of a handle connected to the head, the first part having a first surface; (b) providing the head with at least one cleaning element; and (c) attaching a second part of the handle to the first part of the handle, which second part has a second surface and houses an assembly comprising a timer and a user-notification device that is configured to output a notification in dependence on a state of the timer, so that the first part is connected to the head at a distal end of the handle, the second part defines a proximal end of the handle, and the first and second surfaces together define an exterior surface of the handle.

BACKGROUND OF THE INVENTION

Oral care implements, especially toothbrushes, are used by many peopleon a daily basis. Typical oral care implements comprise an elongatehandle and a head connected to one end of the handle. The handleprovides a structure by which a user grips and manipulates the oral careimplement during use. The head typically comprises one or more elementsdesigned to perform their intended function, such as teeth cleaningelements, soft tissue cleaning elements, and/or oral care agents.

The effectiveness of an oral care implement at cleaning teeth, softtissue surfaces, or performing its other intended function(s) typicallydepends upon the duration for which it is used during an oral caresession. A user of an oral care implements may not register for how longthey have been using the oral care implement during an oral caresession, or they may not know an advisable, recommended or suitableduration for which the oral care implement should be used during any oneoral care session in order to achieve a desired result or effect.

Over the years, efforts have been made to provide oral care implementswith systems for indicating to a user for how long they have been usingthe implement during an oral care session or for how long they shouldcontinue to use the implement during an oral care session. Such effortshave included the development of a toothbrush having a clear handle withan internal chamber that houses an illumination member, illumination ofwhich is controlled by a timing circuit. A flexible grip housing thetiming circuit, a switch for activating the timing circuit, and a powersource for the timing circuit and the illumination member is connectedto an end of the handle.

Despite these efforts, a need still exists for an oral care implementhaving a system for indicating elapse of time to a user, which systemallows for a portion of handle of the implement that is intended to begripped to be more compact and/or better ergonomically designed to begripped. A need also still exists for an oral care implement having amore robust system for indicating elapse of time to a user. A needfurther exists for an oral care implement having a system for indicatingelapse of time to a user, which implement is more easily manufactured orassembled.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a method ofmanufacturing an oral care implement, comprising: (a) providing a headand a first part of a handle connected to the head, the first parthaving a first surface; (b) providing the head with at least onecleaning element; and (c) attaching a second part of the handle to thefirst part of the handle, which second part has a second surface andhouses an assembly comprising a timer and a user-notification devicethat is configured to output a notification in dependence on a state ofthe timer, so that the first part is connected to the head at a distalend of the handle, the second part defines a proximal end of the handle,and the first and second surfaces together define an exterior surface ofthe handle.

Optionally, step (b) precedes step (c). Alternatively, step (c) precedesstep (b), or steps (b) and (c) are carried out simultaneously.

Preferably the method comprises, prior to step (c), a step of insertingat least part of the assembly into a cavity of the second part of thehandle.

The assembly may comprise a printed circuit board upon which the timerand the user-notification device are mounted. The step of inserting maycomprise inserting the printed circuit board into the cavity of thesecond part of the handle so that the printed circuit board lies in aplane that is parallel to a longitudinal axis of the implement.

Optionally, the assembly and the cavity of the second part are shaped toprevent rotation of the assembly relative to the second part about alongitudinal axis of the implement.

Optionally, the assembly comprises one or more elements that preventmovement of the assembly relative to the second part in a direction witha component parallel to a longitudinal axis of the implement. The methodmay comprise, after the step of locating the assembly in the cavity andprior to step (c), a step of providing the one or more elements to theassembly. The step of providing the one or more elements may comprisesoldering or adhering the one or more elements to a portion of theassembly.

Preferably, step (c) comprises bringing one or moreelectrically-conductive contacts of the assembly into surface contactwith one or more respective electrically-conductive contacts comprisedin the first part.

As used herein, the term “surface contact” means that the two or moreelements in contact are not adhered or otherwise fixed together, butinstead are merely touching each other.

The method may comprise providing a power source and a motor that isconnectable to the power source. Optionally, the method comprisesdisposing at least one of the power source and the motor in the firstpart. The method may comprise disposing the power source between themotor and the assembly. The method may comprise electrically connectingthe motor and the assembly to the power source. The method may compriseelectrically connecting the motor and the assembly in parallel to thepower source. The power supply may consist of one, two or a plurality ofbatteries or cells.

Preferably, step (c) comprises bringing an electrically-conductivecontact of the assembly into surface contact with a power sourcedisposed in a chamber of the first part.

Step (c) may comprise attaching the second part to the first part by oneor more of: adhering, welding, and engaging respective mechanicalelements of the first and second parts.

Step (c) may comprise detachably coupling the second part to the firstpart. Optionally, step (c) comprises providing a seal or gasket at aninterface between the first and second parts.

Preferably, the second part is transparent or translucent. Optionally,the first part is opaque.

Optionally, the oral care implement comprises a toothbrush.

A second aspect of the present invention provides an oral careimplement, comprising: a head carrying at least one cleaning element;and a handle having a distal end, a proximal end, a first part and asecond part attached to the first part, wherein a first surface of thefirst part and a second surface of the second part together define anexterior surface of the handle; wherein the first part is connected tothe head at a distal end of the handle and the second part defines theproximal end of the handle; and wherein the second part houses anassembly comprising a timer and a user-notification device that isconfigured to output a notification in dependence on a state of thetimer.

Optionally, the assembly comprises a printed circuit board upon whichthe timer and the user-notification device are mounted. Optionally, theprinted circuit board lies in a plane that is parallel to a longitudinalaxis of the implement.

Preferably, at least part of the assembly is located in a cavity of thesecond part. Further preferably, the assembly and the cavity of thesecond part are shaped to prevent rotation of the assembly relative tothe second part about a longitudinal axis of the implement. At leastpart of the assembly may be located in a cavity of the second part, andthe assembly may comprise one or more elements disposed relative to thecavity to prevent movement of the assembly relative to the second partin a direction with a component parallel to a longitudinal axis of theimplement.

Preferably, the assembly comprises one or more electrically-conductivecontacts in surface contact with one or more respectiveelectrically-conductive contacts comprised in the first part.

Optionally, the implement comprises a power source and a motor that isconnectable to the power source. At least one of the power source andthe motor may be disposed in the first part. The power source may bedisposed between the motor and the assembly. The motor and the assemblymay be electrically connected to the power source. The motor and theassembly may be electrically connected in parallel to the power source.The power supply may consist of one, two or a plurality of batteries orcells.

Optionally, the assembly comprises an electrically-conductive contact insurface contact with a power source disposed in a chamber of the firstpart.

The second part may be attached to the first part by one or more of: anadhesive, a welded joint, and respective engaged mechanical elements ofthe first and second parts.

The second part may be detachably coupled to the first part. A seal orgasket may be provided at an interface between the first and secondparts.

Preferably, the second part is transparent or translucent. Optionally,the second part is made from styrene acrylonitrile resin (SAN).Optionally, the first part is opaque.

Optionally, the assembly comprises a controller, such as amicrocontroller. The controller may have an apparatus comprising atleast one processor and at least one memory including computer programcode, the at least one memory and the computer program code configuredto, with the at least one processor, cause the apparatus to track time.

The timer may be configured such that a state of the timer changes overtime, and the user-notification device may be configured to output afirst predetermined notification when the timer is in a first state andto output a second predetermined notification when the timer is in asecond state. Preferably, the second predetermined notification is of adifferent form to the first predetermined notification. The secondpredetermined notification may have a different duration, pattern orfrequency to the first predetermined notification.

Preferably, the user-notification device comprises a device configuredto output a notification, or notifications, by emitting visible light.The device may comprise at least one light emitting diode (LED).

Optionally, the user-notification device is configured to output apredetermined notification in dependence on a state of the power source.

Preferably, a majority of the exterior surface of the handle is definedby the first surface of the first part. The second part may comprise acap attached to the first part.

Optionally, the oral care implement comprises a toothbrush.

A third aspect of the present invention provides a kit of parts for anoral care implement, the kit of parts comprising: a head carrying atleast one cleaning element; a first part of a handle, which first partis connected to the head and has a first surface; and a second part ofthe handle, which second part has a second surface and houses anassembly comprising a timer and a user-notification device that isconfigured to output a notification in dependence on a state of thetimer; wherein the second part is attachable to the first part so thatthe first part is connected to the head at a distal end of the handle,the second part defines a proximal end of the handle, and the first andsecond surfaces together define an exterior surface of the handle.

The second part may be detachably couplable to the first part.

The components of the kit may have any of the above-described optionalfeatures of the oral care implement of the second aspect of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an oral care implement according to anembodiment of the present invention;

FIG. 2 is a perspective view of a printed circuit board of the oral careimplement of FIG. 1 during manufacture of the implement;

FIG. 3 is a perspective view of a second part of a handle of the oralcare implement of FIG. 1 during manufacture of the implement;

FIG. 4 is a perspective view of the printed circuit board of FIG. 2inserted into the second part of the handle of FIG. 3 during manufactureof the implement of FIG. 1;

FIG. 5 is a perspective view of a pair of electrically-conductivecontacts for attachment to the printed circuit board;

FIG. 6 is a cross sectional view of the components shown in FIG. 4 withthe pair of electrically-conductive contacts of FIG. 5 attached to theprinted circuit board;

FIG. 7 is a perspective view of a first component of a first material,which first component forms a head and a first portion of the first partof the handle of the oral care implement of FIG. 1 during manufacture ofthe implement;

FIG. 8 is a perspective view of the components shown in FIG. 7 afterovermolding of a second component of a second material onto the firstcomponent;

FIG. 9 is a perspective view of a plate carrying cleaning elements; and

FIG. 10 is a perspective view of the components shown in FIG. 8 with theplate of FIG. 9 attached to the head of the first component.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses. The description of illustrative embodimentsaccording to principles of the present invention is intended to be readin connection with the accompanying drawings, which are to be consideredpart of the entire written description. In the description ofembodiments of the invention disclosed herein, any reference todirection or orientation is merely intended for convenience ofdescription and is not intended in any way to limit the scope of thepresent invention. Relative terms such as “lower,” “upper,”“horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and“bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing underdiscussion. These relative terms are for convenience of description onlyand do not require that the apparatus be constructed or operated in aparticular orientation unless explicitly indicated as such. Terms suchas “attached,” “affixed,” “connected,” “coupled,” “interconnected,” andsimilar refer to a relationship wherein structures are secured orattached to one another either directly or indirectly throughintervening structures, as well as both movable or rigid attachments orrelationships, unless expressly described otherwise. Moreover, thefeatures and benefits of the invention are illustrated by reference tothe preferred embodiments. Accordingly, the invention expressly shouldnot be limited to such preferred embodiments illustrating some possiblenon-limiting combination of features that may exist alone or in othercombinations of features.

In the following description, the invention is embodied in a vibratableoral care implement, more specifically a vibratable toothbrush. However,in another embodiment, the invention is embodied in a manually-operated,non-vibratable toothbrush, and in another embodiment the invention isembodied in a powered toothbrush wherein one or more cleaning elementsprovided to the head of the implement are drivable so as to be movedrelative to the handle of the implement. In still further embodiments,the invention may be embodied in other forms of oral care implements,such as a soft-tissue cleansing implement, an inter-proximal pick, aflossing tool, a plaque scraper, or another ansate implement designedfor oral care. It is to be understood that other embodiments may beutilised, and that structural and functional modifications may be madewithout departing from the scope of the present invention.

FIG. 1 illustrates an oral care implement, in this case a toothbrush,according to a first embodiment of the present invention, generallydesignated with the reference numeral 100. The toothbrush 100 has asupport 110 including a handle 120 and a head 140. A neck 130 of thehandle 120 connects the handle 120 to the head 140, and at least onecleaning element 200 is carried by the head 140. The head 140 is an endportion of the support 110 provided with the at least one cleaningelement 200. In this embodiment, the head 140 carries a plurality ofcleaning elements 200.

In this embodiment, the cleaning elements 200 comprise a plurality oftooth cleaning elements, more specifically a plurality of flexible,nylon bristles arranged in tufts. However, in variations to thisembodiment, the cleaning elements 200 may additionally or alternativelycomprise at least one of any one or more of the following, withoutlimitation: bristles, rigid bristles, flexible bristles, filamentbristles, fibre bristles, nylon bristles, spiral bristles, rubberbristles, elastomeric protrusions, elastomeric elements, flexiblepolymer protrusions, co-extruded filaments, flag bristles, crimpedbristles, anti-bacterial bristles and combinations thereof and/orstructures containing such materials or combinations.

The head 140 has a first, proximal end 141 and a second, distal end 142.The handle 120 has a first, proximal end 121 and a second, distal end122. The neck 130 is located at the distal end 122 of the handle 120.The distal end 122 of the handle 120 is connected to the proximal end141 of the head 140. The neck 130 is generally of a narrower crosssectional area than the head 140 and the rest of the handle 120.

The handle 120 provides the user with a mechanism by which he/she canreadily grip and manipulate the toothbrush 100, includes ergonomicfeatures which provide a high degree of control for the user whilemaintaining comfort, and may be formed of many different shapes and witha variety of constructions.

Generally, the toothbrush 100 extends from a proximal end 101 (which isalso the proximal end 121 of the handle 120) to a distal end 102 (whichis also the distal end 142 of the head 140) along a longitudinal axisA-A. Although the handle 120 is a non-linear structure in theillustrated embodiment, the longitudinal axis A-A of the implement 100is linear in the illustrated embodiment. However, the invention is notso limited, and in certain embodiments, the implement 100 may have asimple linear handle 120 that is longitudinally aligned along the linearlongitudinal axis A-A of the implement 100.

The head 140 is connected to the handle 120 via the neck 130 of thehandle 120. In this embodiment, the head 140 and a first part 123 of thehandle 120 (including the neck 130) are formed as an integral structureusing an injection molding process. The head 140 and the first part 123of the handle 120 together comprise a unitary structure. However, inother embodiments, the head 140 and the first part 123 of the handle 120may be formed as separate components which are operably connected at alater stage of the manufacturing process by any suitable technique knownin the art, including without limitation thermal welding, sonic welding,a tight-fit assembly, a coupling sleeve, adhesion, fasteners, and asnap-fit connection. Whether the head 140 and the first part 123 of thehandle 120 are constructed as a single piece or a multi-piece assembly(including connection techniques) is not limiting of the presentinvention in all embodiments. Furthermore, other manufacturingtechniques may be used in place of and/or in addition to injectionmolding to create the first part 123 of the handle 120 and/or the head140 (or components thereof), such as milling and/or machining.

In this embodiment, the head 140 and the first part 123 of the handle120 are together constructed of a first component 10 of polypropylene(PP) and a second component 20 of an elastomer, such as a thermoplasticelastomer (TPE), which has been overmolded onto the first component 10,as discussed in more detail below. However, in variations to thisembodiment, the first component 10 may instead or additionally compriseone or more of the following materials: polyethylene, polyamide,polyester, cellulosics, styrene-acrylonitrile (SAN), acrylic,acrylonitrile butadiene styrene (ABS) and a thermoplastic. In variationsto this embodiment, the second component 20 may instead or additionallycomprise styrene-ethylene/butylene-styrene (SEBS) or one or more of thematerials listed in the preceding sentence.

The head 140 generally comprises a front surface, on a front side 143 ofthe head 140, and a rear surface, on a rear side 144 of the head 140opposite to the front side 143. The front surface and the rear surfaceof the head 140 can take on a wide variety of shapes and contours, noneof which are limiting of the present invention. For example, the frontand rear surfaces can be planar, contoured or combinations thereof. Thefront surface and rear surface are joined by a peripheral or lateralsurface 145 of the head 140. The cleaning elements are provided on, andextend outward from, the front side 143 of the head 140 for cleaningcontact with an oral surface, preferably teeth.

While the plural cleaning elements 200 are particularly suited forcleaning teeth, the cleaning elements 200 can be used to clean oral softtissue, such as a tongue, gums, or cheeks instead of or in addition toteeth. As used herein, the term “cleaning element” is used in a genericsense to refer to any structure that can be used to clean, massage orpolish an oral surface, such as teeth or soft tissue, through relativesurface contact.

Indeed, in a variation to the embodiment shown in FIG. 1, instead of aplurality of tooth cleaning elements 200, there is instead provided atleast one soft tissue cleaning element, such as a tongue scrapercomprising at least one blade. Preferably, the, or each, blade has itslongitudinal length disposed so as to extend across the front side 143of the head 140 in a direction non-parallel or perpendicular to thelongitudinal axis A-A.

On the rear side 144 of the head 140, the head 140 comprises a softtissue cleaning element 170. The soft tissue cleaning element 170comprises a plurality of flexible protrusions 172. The protrusions 172and the rest of the soft tissue cleaning element 170 are a unitarycomponent. The soft tissue cleaning element 170 and the protrusions 172are formed by the second component 20.

The handle 120 is formed of the first part 123 and a second part 124,which is a separate component in the form of a cap that has beenattached to the first part 123. While the first part 123 is connected tothe head 140 at the distal end 122 of the handle 120, the second part124 defines the proximal end 121 of the handle 120, indeed the proximalend 101 of the implement 100. A first surface 123 a of the first part123 and a second surface 124 a of the second part 124 together define anexterior surface 125 of the handle 120. At least the first surface 123 ais to be gripped by a user's hand during an oral care session, so thatthe user can manipulate the toothbrush 100. As will be appreciated onconsideration of FIG. 1, a majority of the exterior surface 125 of thehandle 120 is defined by the first surface 123 a of the first part 123.In particular, the second surface 124 a of the second part 124 definesless than 20%, perhaps less than 10%, of the exterior surface 125 of thehandle 120.

The first and second components 10, 20 are shaped to provide the handle120 with ergonomic features which provide a high degree of control forthe user while maintaining comfort. Moreover, the second component 20forms grip regions of the exterior surface 125 of the handle 120 thathave a greater coefficient of friction than regions of the exteriorsurface 125 formed by the first component 10.

The first part 123 is opaque. However, the second part 124 istransparent, i.e. is formed of a transparent material. In thisembodiment, the second part 124 is made from styrene acrylonitrile resin(SAN) and is attached to the first part 123 of the handle 120 by anadhesive. In other embodiments, the first and second parts 123, 124 ofthe handle 120 may be attached to each other by other mechanisms, suchas a welded joint or respective engaged mechanical elements of the firstand second parts 123, 124. In variations to these embodiments, thesecond part 124 is translucent, i.e. is formed of a translucentmaterial.

In variations to the illustrated embodiment, the second part 124 isdetachably coupled to the first part 123, as described in more detailbelow.

The second part 124 houses an assembly 300 comprising a printed circuitboard 302 upon which are mounted a controller 304, such as amicrocontroller, and a light emitting diode (LED) 306. The LED 306 ispart of a user-notification device that is configured to output anotification in dependence on a state of a timer comprised in thecontroller 304. In this embodiment, the user-notification devicecomprises the LED 306, which is able to emit light that is visible to auser through the transparent second part 124 of the handle 120. However,in variations to this embodiment, the user-notification device maycomprise an element, other than an LED, that is configured to outputnotifications by emitting visible light. In still further variations,the user-notification device may comprise an element that is configuredto output a notification by means other than emitting visible light,such as a buzzer or speaker configured to output notifications byemitting sound, or a vibrator configured to output notifications byvibrating.

The printed circuit board 302 is located in an internal cavity 124 b ofthe second part 124 and lies in a plane that is parallel to thelongitudinal axis A-A of the implement 100. The assembly 300 and thecavity 124 b of the second part 124 are each shaped to prevent rotationof the assembly 300 relative to the second part 124 about thelongitudinal axis A-A of the implement 100. That is, in this embodiment,the cavity 124 b comprises a slot, and the printed circuit board 302 hasa rectangular cross-sectional area in a plane perpendicular to thelongitudinal axis A-A that is coincident with a rectangularcross-sectional area of the slot in the same plane.

Moreover, the assembly comprises first and secondelectrically-conductive contacts 310, 320 having respective proximalterminals 314, 324 soldered to respective electrically-conductiveelements 308 a, 308 b mounted on the printed circuit board 302. Theelectrically-conductive elements 308 a, 308 b are electrically connectedto the microprocessor 304. The contacts 310, 320 are disposed relativeto the cavity 124 b to prevent movement of the assembly 300 relative tothe second part 124 in a direction with a component parallel to thelongitudinal axis A-A of the implement 100. More particularly, as shownin FIG. 6, respective main bodies 312, 322 of the first and secondcontacts 310, 320 extend in a direction perpendicular to thelongitudinal axis A-A and through respective holes 124 c in a wall 124 dof the second part 124. Portions of the wall 124 d are disposed eitherside of the holes 124 c in the longitudinal direction of the implement100, so as to prevent movement of the assembly 300 relative to thesecond part 124 in the longitudinal direction.

In the assembled implement 100, respective distal terminals 316, 326 ofthe contacts 310, 320 are in surface contact with respectiveelectrically-conductive contacts (of which only one is shown in FIG. 7and indicated with reference numeral 408) comprised in the first part123. Moreover, in the assembled implement 100, a further resilientterminal 318 of the first contact 310 of the assembly 300 is in surfacecontact with a battery or other power source disposed in a chamber 123 bof the first part 123, as described in more detail below.

FIG. 6 illustrates the second part 124 housing the assembly 300, albeitwhen the second part 124 is not attached to the first part 123 of thehandle 120. As shown in FIG. 6, the assembly 300 comprises thecontroller 304. The controller 304 has an apparatus comprising at leastone processor (not expressly shown) and at least one memory (notexpressly shown) including computer program code, and the at least onememory and the computer program code are configured to, with the atleast one processor, cause the apparatus to track time. In other words,the controller 304 comprises a timer, since the software resident on thecontroller 304 tracks time. Moreover, the controller 304 comprises partof the user-notification device, in order that the user-notificationdevice is configured to output one or more notifications in dependenceon the state of the timer. The user-notification device also comprisesthe LED 306.

The timer is activated by a user closing a switch comprised in the firstpart 123 of the handle 120. More specifically, the user presses on afirst defined region 126 of the first surface 123 a of the first part123 that is formed of the second component 20. The defined region 126 isresilient, so the user's application of a force on the defined region126 causes the defined region 126 to deform. In turn, this deformationcauses the switch at a side of the defined region 126 interior to thefirst part 123 of the handle 120 to be closed, which completes anelectric circuit including a motor 500 (discussed below), the controller304, the battery or other power source disposed in the internal chamber123 b of the first part 123, and wires 501-504, as described in moredetail below. Thus, as a result of the switch being closed, the motorand controller 304 receive electric power, which causes the motor 500 torotate and the timer embodied in the controller 304 to be activated totrack time.

Although not expressly shown in the Figures, a mechanical vibratorydevice, such as an eccentric, is mounted on an output shaft of the motor500 whereby, when the motor 500 rotates, the mechanical vibratory devicerotates about the axis of the output shaft of the motor 500, causing thehead 140 of the implement 100 to vibrate, which increases the efficiencywith which the cleaning elements 200 clean an oral surface during use ofthe implement 100.

Since the timer tracks time, a state of the timer changes over time. Invarious different embodiments, the user-notification device isconfigured to output one or more notifications (such as by causing theLED 306 to emit light) in dependence on the state of the timer. Forexample, in the present embodiment, the controller 304 tracks time and,in accordance with commands included in the computer program code,causes the LED 306 to adopt a different lighting pattern in dependenceon the length of time that has elapsed since the timer was activated. Inthis embodiment, for a first period of 30 seconds starting when thetimer was activated, the controller 304 causes the LED 306 to emitsingle flashes of light with pauses of equal duration between the singleflashes. For a second period of 30 seconds following the first period,the controller 304 causes the LED 306 to emit successive pairs of singleflashes of light with first pauses of equal duration between the pairsand second pauses of equal duration between the single flashes of eachpair, wherein each of the first pauses is longer, preferably at leasttwo or three times as long, than each of the second pauses. In otherembodiments, the first period may be of the same or a different durationto the second period. The first and/or the second period may be, forexample, of any of the following durations: 10 seconds, 15 seconds, 20seconds, 30 seconds, and 60 seconds. In other embodiments, still furtherlighting patterns may be employed. In any event, preferably theuser-notification device is configured to output a first predeterminednotification when the timer is in a first state and to output a secondpredetermined notification when the timer is in a second state, whichsecond predetermined notification is of a different form to the firstpredetermined notification. The second predetermined notification mayhave a different duration, pattern and/or frequency than the firstpredetermined notification.

Accordingly, during use of the oral care implement 100, the user isnotified of an elapse of time, specifically an elapse of time since thefirst switch was closed. When the user has completed their oral caresession, they open the switch comprised in the first part 123 of thehandle 120. More specifically, the user presses on a second definedregion 127 of the first surface 123 a of the first part 123 that isformed of the second component 20. The second defined region 127 also isresilient, so the user's application of a force on the second definedregion 127 causes the second defined region 127 to deform. In turn, thisdeformation causes the switch to be opened, which breaks the electriccircuit. In this embodiment, the controller 304 has no ability to recordconditions of use of the implement 100 during the completed oral casesession, so the software resident in the controller 304 resets to adefault initial state once the electric circuit has been broken.Accordingly, when the switch is subsequently closed again, thecontroller 304 will carry out the same process as described above.

The motor 500 and power source (not shown) discussed above are comprisedin the first part 123 of the handle 120, as shown in FIG. 7. Moreparticularly, the motor 500 is located in the neck 130 of the handle 120of the implement 100. In the assembled implement 100, the power sourceis disposed between the motor 500 and the assembly 300. As discussedabove, the motor 500 is connectable to the power source by way of a userclosing the switch. It is to be noted that, in this embodiment, themotor 500 and the assembly 300 are electrically connected in parallel tothe power source. In particular, the motor 500 is connected to the powersource by a first pair of wires 501, 502, and the assembly 300 isconnected to the power source by a parallel second pair of wires 503,504.

In this embodiment, the motor 500 and the assembly 300 (including thetimer and the user-notification device, and thus including thecontroller 304 and the LED 306) are connected, in parallel, to the sameshared power supply, so that the motor 500 and the assembly 300 are ableto be electrically powered by the power supply. The power supply mayconsist of one, two or a plurality of batteries or cells, disposed inthe chamber 123 b of the first part 123. In another embodiment, themotor 500 and the assembly 300 (including the timer and theuser-notification device, and thus including the controller 304 and theLED 306) are connected, in series, to the same shared power supply, sothat the motor 500 and the assembly 300 are able to be electricallypowered by the power supply.

In the above-mentioned variations to the illustrated embodiment, inwhich the second part 124 is detachably coupled to the first part 123,the second part 124 may be detachably coupled to the first part 123 byany of a tight-fit, twist-and-lock, snap-fit and threaded connection. Itcan be considered that an interface is provided between the first andsecond parts 123, 124 where the first and second parts 123, 124 areconnected to each other. In some embodiments, a compressible orresilient gasket or seal is provided at the interface. The gasket orseal may be formed of TPE and/or may be part of the second component 20.Preferably the gasket or seal surrounds the interface. Preferably, thegasket or seal becomes compressed during coupling of the second part 124to the first part 123 whereby, in the assembled implement 100, thegasket or seal is in a compressed state and prevents or minimises fluidflow from an exterior of the first and second parts 123, 124 into thechamber 123 b and/or into the cavity 124 b. Accordingly, the gasket orseal seals the assembly 300, motor 500 and power supply from waterduring use of the assembled implement 100, yet the ability to detach thesecond part 124 from the first part 123 permits replacement of the powersupply and/or maintenance of the assembly 300, if required.

In this embodiment, the user-notification device is configured to outputa predetermined notification in dependence on a state of the powersource. In this embodiment, the controller 304 monitors the state of thepower source, such as the remaining charge in the power source and, whenthe remaining charge drops below a predetermined threshold value ofcharge, the user-notification device causes the LED 306 to emit light ina predetermined lighting pattern. The predetermined lighting pattern maycomprise the LED 306 being caused to emit light for a relatively longduration, such as 5 seconds, 10 seconds, 20 seconds, 30 seconds, or 60seconds, or may comprise the LED 306 being caused to emit a rapid burstof flashes of light, such as 5 or 10 distinct flashes per second. Otherpredetermined lighting pattern will be apparent to the skilled person.

Manufacture of the toothbrush 100 shown in FIG. 1 will now be describedwith additional reference to FIGS. 2 to 10.

In a first process of the method of manufacturing the oral careimplement 100, the second part 124 of the handle 120, including the wall124 d, internal cavity 124 b and the holes 124 c in the wall 124 d, isformed, in this embodiment from transparent material by molding thetransparent material. The second part 124 so formed is shown in FIG. 3.

In a second process, which may be performed during, before or after thefirst process, the assembly 300 is assembled. More specifically, theprinted circuit board 302 is provided and the controller 304 (e.g. amicrocontroller), LED 306 and electrically-conductive elements 308 a,308 b are mounted on the printed circuit board 302, as shown in FIG. 2.

After each of the first and second processes has been completed, a thirdprocess is performed in which at least part of the assembly 300 isinserted into the cavity 124 b of the second part 124 of the handle 120,in such a manner that the printed circuit board 302 lies in a plane thatis parallel to the longitudinal axis A-A of the completed implement 100,as shown in FIG. 4. As discussed above, the assembly 300 and the cavity124 b of the second part 124 are shaped to prevent rotation of theassembly 300 relative to the second part 124 about the longitudinal axisA-A of the implement 100.

Following the third process, a fourth process is performed in which thefirst and second contacts 310, 320 (shown in FIG. 5) are provided, andthe respective proximal terminals 314, 324 of the first and secondcontacts 310, 320 are soldered to respective ones of theelectrically-conductive elements 308 a, 308 b mounted on the printedcircuit board 302, so that the respective main bodies 312, 322 of thefirst and second contacts 310, 320 extend in a direction perpendicularto the longitudinal axis A-A and through respective holes 124 c in thewall 124 d of the second part 124, as shown in FIG. 6. Accordingly, thefirst and second contacts 310, 320 act as elements that prevent movementof the assembly 300 relative to the second part 124 in a direction witha component parallel to the longitudinal axis A-A of the completedimplement 100.

A fifth process, which may be performed during, before or after any orall of the first to fourth processes, comprises providing the head 140and the first part 123 of the handle 120 that is connected to the head140. This fifth process involves first forming the first material toform the first component 10 (as shown in FIG. 7). This may be performedin accordance with any method known in the art, such as by injectionmolding the first material into a suitable mould in a molten state andthen allowing the first material to cool and harden. Next, the motor 500is disposed in the neck 130 of the first part 123 of the handle 120, andthe first pair of wires 501, 502 having respective first ends connectedto respective terminals of the motor 500 are routed so that theirrespective second ends, opposite to the first ends, are located withinthe chamber 123 b of the first part 123, via a hole 129 in the firstcomponent 10, for future connection to a power source that will belocated in the chamber 123 b. Also, the second pair of wires 503, 504having respective first ends connected to respectiveelectrically-conductive contacts 408 within the chamber 123 b are routedso that their respective second ends, opposite to the first ends, arelocated within the chamber 123 b of the first part 123, via the hole 129in the first component 10, for future connection to the power source.Finally, the second material forming the second component 20 isovermolded onto the first component 10 to encase the motor 500 and themajority of the two pairs of wires 501, 502, 503, 504. The resultantdevice is shown in FIG. 8. It is to be noted that, in this embodiment,each of the first and second components 10, 20 is opaque.

Optionally at this stage, the power source may be disposed in thechamber 123 b between the motor 500 and an end of the chamber 123 b towhich the second part 124 of the handle 120 is later attached.

A sixth process, which may be performed during, before or after thefirst to fifth processes, involves providing a cleaning elementsub-assembly 600, as shown in FIG. 9. The sub-assembly 600 comprises abase plate 601 and the at least one cleaning element 200 extending fromthe base plate 601. The one or more cleaning elements 200 may beconnected to the base plate 601 by any mechanism known in the art, suchas AFT, IMT, or stapling.

A seventh process, which may be performed after the sixth process,involves attaching the cleaning element sub-assembly 600 to the head140, in order to provide the head 140 with the at least one cleaningelement 200, as shown in FIG. 10. This attaching may involve, forexample, adhering the sub-assembly 600 to the head 140 or sonic weldinga portion of the sub-assembly 600 to the head 140.

An eighth process, which may be performed before, during or after theseventh process, comprises disposing the power source in the chamber 123b (if not already done), and then attaching the second part 124 of thehandle 120 to the first part 123 of the handle 120, so that the firstpart 123 is connected to the head 140 at the distal end 122 of thehandle 120, the second part 124 defines the proximal end 121 of thehandle 120, and the first and second surfaces 123 a, 124 a of the firstand second parts 123, 124 together define the exterior surface 125 ofthe handle 120. The attaching may comprise attaching the second part 124to the first part 123 by one or more of: adhering, welding, and engagingrespective mechanical elements of the first and second parts 123, 124.Alternatively, the attaching may comprise detachably coupling the secondpart 124 to the first part 123, and may optionally also compriseproviding or compressing a seal or gasket between the first and secondparts 123, 124 during the coupling of the second part 124 to the firstpart 123, whereby, in the assembled implement 100, the gasket or seal isin a compressed state and prevents or minimises fluid flow from anexterior of the first and second parts 123, 124 into the chamber 123 band/or into the cavity 124 b.

During the eighth process, the power source becomes disposed between themotor 500 and the assembly 300. Moreover, the distal terminals 316, 326of the contacts 310, 320 are brought into surface contact with therespective electrically-conductive contacts (of which one is shown inFIG. 7 and indicated with reference numeral 408) comprised in the firstpart 123, and the further resilient terminal 318 of the first contact310 of the assembly 300 is brought into surface contact with the powersource disposed in the chamber 123 b of the first part 123, whereby themotor 500 and the assembly 300 become electrically connected in parallelto the power source.

In the present invention, since the assembly 300 is housed in the secondpart 124 of the handle 120, the first part 123 of the handle 120, whichfirst part 123 is intended to be gripped by a user during use of theimplement 100, is able to be made compact and/or better ergonomicallydesigned for gripping by the user. The first part 123 also can be madeof a wide variety of materials, including opaque materials. Moreover,since the assembly 300 including the user-notification device is housedin the second part 124 of the handle, protrusion of parts of theassembly 300 from the second part 124 into the first part 123 of thehandle 120 can be minimised or avoided, which provides a system forindicating elapse of time to a user that is more robust, since parts ofthe assembly 300 are not likely to be knocked or damaged duringmanufacture of the implement 100.

Moreover, the implement 100 is more easily manufactured than known priorart devices including systems for indicating elapse of time to a user,since the majority of the implement 100 is manufacturable independentlyof the system for indicating elapse of time to a user and the provisionof the system for indicating elapse of time to a user requiressignificant modifications only to the second part 124 of the handle 120.Assembly of the implement 100 also is relatively straightforward: thefirst part 123 of the handle 120 can be assembled separately to thesecond part 124 of the handle 120, and the first and second parts 123,124 need only be attached to each other towards or at the end of theassembly process.

The present invention may be embodied as a kit of parts for an oral careimplement 100, the kit of parts comprising: the head 140 carrying the atleast one cleaning element 200; the first part 123 of the handle 120,which first part 123 is connected to the head 140 and has the firstsurface 123 a; and the second part 124 of the handle 120, which secondpart 124 has the second surface 124 a and houses the assembly 300comprising the timer and the user-notification device that is configuredto output a notification in dependence on a state of the timer; whereinthe second part 124 is attachable to the first part 123 so that thefirst part 123 is connected to the head 14D at the distal end 122 of thehandle 120, the second part 124 defines the proximal end 121 of thehandle 120, and the first and second surfaces 123 a, 124 a togetherdefine the exterior surface 125 of the handle 120.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described implements and techniques. It isto be understood that other embodiments may be utilized and structuraland functional modifications may be made without departing from thescope of the present invention. Thus, the scope of the invention shouldbe construed broadly as set forth in the appended claims.

1-47. (canceled)
 48. A method of manufacturing an oral care implement,comprising: (a) providing a head and a first part of a handle connectedto the head, the first part having a first surface; (b) providing thehead with at least one cleaning element; and (c) attaching a second partof the handle to the first part of the handle, which second part has asecond surface and houses an assembly comprising a timer and auser-notification device that is configured to output a notification independence on a state of the timer, so that the first part is connectedto the head at a distal end of the handle, the second part defines aproximal end of the handle, and the first and second surfaces togetherdefine an exterior surface of the handle.
 49. The method of claim 48comprising, prior to step (c), a step of inserting at least part of theassembly into a cavity of the second part of the handle.
 50. The methodof claim 49, wherein the assembly comprises a printed circuit board uponwhich the timer and the user-notification device are mounted, and thestep of inserting comprises inserting the printed circuit board into thecavity of the second part of the handle so that the printed circuitboard lies in a plane that is parallel to a longitudinal axis of theimplement.
 51. The method of claim 49, wherein the assembly and thecavity of the second part are shaped to prevent rotation of the assemblyrelative to the second part about a longitudinal axis of the implement.52. The method of claim 49, wherein the assembly comprises one or moreelements that prevent movement of the assembly relative to the secondpart in a direction with a component parallel to a longitudinal axis ofthe implement.
 53. The method of claim 52, comprising, after the step oflocating the assembly in the cavity and prior to step (c), a step ofproviding the one or more elements to the assembly.
 54. The method ofclaim 53, wherein the step of providing the one or more elementscomprises soldering or adhering the one or more elements to a portion ofthe assembly.
 55. The method of claim 48, wherein step (c) comprisesbringing one or more electrically-conductive contacts of the assemblyinto surface contact with one or more respective electrically-conductivecontacts comprised in the first part.
 56. An oral care implement,comprising: a head carrying at least one cleaning element; and a handlehaving a distal end, a proximal end, a first part and a second partattached to the first part, wherein a first surface of the first partand a second surface of the second part together define an exteriorsurface of the handle; wherein the first part is connected to the headat a distal end of the handle and the second part defines the proximalend of the handle; and wherein the second part houses an assemblycomprising a timer and a user-notification device that is configured tooutput a notification in dependence on a state of the timer.
 57. Theoral care implement of claim 56, wherein the assembly comprises aprinted circuit board upon which the timer and the user-notificationdevice are mounted.
 58. The oral care implement of claim 57, wherein theprinted circuit board lies in a plane that is parallel to a longitudinalaxis of the implement.
 59. The oral care implement of claim 56, whereinat least part of the assembly is located in a cavity of the second part,and wherein the assembly and the cavity of the second part are shaped toprevent rotation of the assembly relative to the second part about alongitudinal axis of the implement.
 60. The oral care implement of claim56, wherein at least part of the assembly is located in a cavity of thesecond part, and wherein the assembly comprises one or more elementsdisposed relative to the cavity to prevent movement of the assemblyrelative to the second part in a direction with a component parallel toa longitudinal axis of the implement.
 61. The oral care implement ofclaim 56, wherein the assembly comprises one or moreelectrically-conductive contacts in surface contact with one or morerespective electrically-conductive contacts comprised in the first part.62. The oral care implement of claim 56, comprising a power source and amotor that is connectable to the power source; wherein at least one ofthe power source and the motor is disposed in the first part; whereinthe power source is disposed between the motor and the assembly; andwherein the motor and the assembly are electrically connected inparallel to the power source.
 63. The oral care implement of claim 56,wherein the assembly comprises a controller, such as a microcontroller;and wherein the controller has an apparatus comprising at least oneprocessor and at least one memory including computer program code, theat least one memory and the computer program code configured to, withthe at least one processor, cause the apparatus to track time.
 64. Theoral care implement of claim 56, wherein the timer is configured suchthat a state of the timer changes over time, and wherein theuser-notification device is configured to output a first predeterminednotification when the timer is in a first state and to output a secondpredetermined notification when the timer is in a second state, whichsecond predetermined notification is of a different form to the firstpredetermined notification; and wherein the second predeterminednotification has a different duration, pattern or frequency to the firstpredetermined notification.
 65. The oral care implement of claim 56,wherein the user-notification device comprises a device configured tooutput a notification, or notifications, by emitting visible light; andwherein the device comprises at least one light emitting diode.
 66. Akit of parts for an oral care implement, the kit of parts comprising: ahead carrying at least one cleaning element; a first part of a handle,which first part is connected to the head and has a first surface; and asecond part of the handle, which second part has a second surface andhouses an assembly comprising a timer and a user-notification devicethat is configured to output a notification in dependence on a state ofthe timer; wherein the second part is attachable to the first part sothat the first part is connected to the head at a distal end of thehandle, the second part defines a proximal end of the handle, and thefirst and second surfaces together define an exterior surface of thehandle.
 67. The kit of parts of claim 66, wherein the second part isdetachably couplable to the first part.